Semiconductor device having conductive via and manufacturing process for same

ABSTRACT

In accordance with the present invention, there is provided a semiconductor device comprising a semiconductor die or chip, a package body and a through package body via. The semiconductor chip includes a plurality of conductive pads. The package body encapsulates a sidewall of the semiconductor chip, and has at least one hole formed therein having a sidewall which is of a prescribed first surface roughness value. The through package body via is disposed in the hole of the package body and comprises a dielectric material and at least one conductive interconnection metal. The dielectric material is disposed on the sidewall of the hole and defines at least one bore having a sidewall which is of a second surface roughness value less than the first surface roughness value. The interconnection metal is disposed within the bore.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 13/721,599 entitled SEMICONDUCTOR DEVICE HAVING CONDUCTIVE VIAAND MANUFACTURING PROCESS FOR SAME filed Dec. 20, 2012.

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to semiconductor devices and,more particularly, to a semiconductor package and corresponding processfor fabricating the same.

2. Description of the Related Art

As is known in the electrical arts, conventional fan-out semiconductorpackages typically comprises at least one conductive via formed withinthe package body of the package. In the manufacturing process for suchsemiconductor packages, the package body of the package is drilledthrough the use of a laser to form at least one via hole therein. Thisvia hole is then plated and thereafter filled with conductive metals soas to form the conductive via. In conventional fan-out semiconductorpackages, the package body is a composite material which includes epoxyresin and SiO2 fillers. Because the laser absorbability characteristicsof the epoxy resin and SiO2 fillers are different, and the sizes of theSiO2 fillers typically vary from 10 to 100 μm, the circularity of thesidewall of the via hole is often poor, the surface roughness ofsidewall of the hole is high, and the size of the hole is larger thanoptimal upon the completion of the aforementioned laser-drillingprocess. These particular deficiencies arise despite the use of highaccuracy lasers for the drilling process. As a result, in the process offorming the conductive via as described above, the plating andsubsequent hole-filling processes process are complex and time consumingwhich increases the associated costs, with the plating quality furtherbeing difficult to control.

More particularly, in conventional fan-out semiconductor packages, theplating of the via hole is facilitated through the use of a sputteringprocess. In the sputtering machine, the plating material is dispensedtherefrom in a manner in which it enters a corresponding via hole in adirection which is generally parallel to the sidewall of the hole. Thisdirection of entry into the hole, coupled with the extremely smallparticle sizes of the plating material being dispensed from thesputtering machine, often results in the fillers hindering the complete,uniform application of the plating layer to the sidewall. In thisregard, the surface roughness of the sidewall of the hole isattributable to such sidewall being partially defined by portions of thefillers which protrude from the epoxy. Whereas the plating layer istypically applied to the top sides of the exposed fillers which face thesputtering machine, the opposite bottom sides of these fillers oftenhave no plating layer applied thereto by the sputtering process. As aresult, when a metal such as copper is ultimately filled into the holeto complete the formation of the conductive via, such metal materialwill easily adhere to the plating layer, but will not easily adhere tothose areas of the sidewall (e.g., the undersides of the fillers) whichdo not have the plating layer applied thereto. This lack of adhesiontypically results in the formation of voids, which could compromise theintegrity of the conductive path defined by the via. Though thepotential for such incomplete plating, and the resultant formation ofvoids, can be reduced by increasing the amount of material applied in(and thus the time taken to time to complete) the sputtering process,this gives rise to an undesirable increase in cost coupled with adecrease in productivity.

The present invention addresses and overcomes these deficiencies byproviding a semiconductor device and corresponding process forfabricating the same wherein the semiconductor device includes at leastone conductive via collectively defined by several materials ofdiffering properties as optimizes both the manufacturability andfunctionality thereof. These, as well other features and advantages ofthe present invention, will be described in more detail below.

BRIEF SUMMARY OF THE INVENTION

In accordance with one embodiment of the present invention, there isprovided a semiconductor device comprising a semiconductor die or chip,a package body and a through package body via. The chip has an activesurface and a plurality of pads disposed adjacent to the active surface.The package body encapsulates a sidewall of the chip, and has at leastone hole formed therein including a sidewall which is of a prescribedfirst surface roughness value. The through package body via is disposedin the hole of the package body and comprises a dielectric material andat least one conductive interconnection metal. The dielectric materialis disposed on the sidewall of the hole and defines at least one borehaving a sidewall which is of a second surface roughness value. Thesecond surface roughness value of the sidewall of the bore is less thanthat of the first surface roughness value of the sidewall of the hole.The interconnection metal is disposed within the bore.

In accordance with another embodiment of the present invention, thesemiconductor device may also comprise a patterned conductive layer. Thepatterned conductive layer is disposed adjacent to the active surface ofthe chip and electrically connects the pads of the chip to theinterconnection metal of the through package body via which is disposedin the hole of the package body. In addition, a portion of thedielectric material disposed on the sidewall of the hole in the packagebody may further partially cover a first surface of the package body.

In accordance with yet another embodiment the present invention thepresent invention, there is provided a method or process for fabricatingthe aforementioned semiconductor device. An exemplary process comprisesthe steps of: (a) forming the at least one hole in the package body, thehole being of the prescribed first surface roughness value; (b) fillingthe at least one hole with the dielectric material; (c) forming at leastone bore in the dielectric material, the bore being of the prescribedsecond surface roughness value which is less than that of the firstsurface roughness value; and (d) filling the bore with theinterconnection metal.

BRIEF DESCRIPTION OF THE DRAWINGS

These, as well as other features of the present invention, will becomemore apparent upon reference to the drawings wherein:

FIG. 1 is a cross-sectional view of a semiconductor device constructedin accordance with a first embodiment of the present invention;

FIG. 2 is an enlargement of the encircled region B shown in FIG. 1;

FIG. 3 is an enlargement of the encircled region A shown in FIG. 1;

FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 3;

FIG. 5 is a top plan view of the semiconductor device shown in FIG. 1,wherein the second openings of the second passivation layer, the solderballs, the patterned conductive layer and the surface seed layer of thesemiconductor device are omitted;

FIG. 6 is a top plan view of a semiconductor device constructed inaccordance with a second embodiment of the present invention;

FIG. 7 is a cross-sectional view taken along line 7-7 of FIG. 6;

FIGS. 8-21 illustrate an exemplary sequence of steps which may be usedto facilitate the fabrication of the semiconductor device shown in FIGS.1-5; and

FIGS. 22-27 illustrate an exemplary sequence of steps which may be usedto facilitate the fabrication of the semiconductor device shown in FIGS.6-7.

Common reference numerals are used throughout the drawings and thedetailed description to indicate the same elements. The presentinvention will be more apparent from the following detailed descriptiontaken in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, there is depicted a semiconductor device 1constructed in accordance with one embodiment of the present invention.The semiconductor device 1 comprises a semiconductor die or chip 2, apackage body 12, an upper redistribution layer (RDL) disposed overportions of the semiconductor chip 2 and an upper surface of the packagebody 12, a lower RDL disposed over portions of a lower surface of thepackage body 12 and at least one conductive via 15 formed in a throughhole 123 which interconnects the upper RDL with the lower REML.

The semiconductor chip 2 includes an active surface 21, and an opposedbackside surface 22. Extending between the active and backside surfaces21, 22 is a peripheral side surface 25. Disposed on the active surface21 is a plurality of conductive terminals or pads 23. Also disposed onthe active surface 21 is a protective layer 24. The protective layer 24,which is preferably a nitride layer or an oxide layer, includes aplurality of openings 241 formed therein which expose respective ones ofthe pads 23.

The package body 12 partially encapsulates the semiconductor chip 2. Thepackage body 12 also covers or encapsulates both the side surface 25 andthe backside surface 22 of the semiconductor chip 2. The package body 12defines a first surface 121 which is substantially continuous orcoplanar with the active surface 21 of the semiconductor chip 2, and asecond surface 122 which is disposed in opposed relation to the firstsurface 121. The package body 12 may be comprised of a molding compoundsuch as an epoxy resin.

The upper RDL includes a first passivation layer 14, an upper patternedsurface seed layer 182, an upper patterned conductive layer 31, and asecond passivation layer 32. The first passivation layer 14 covers theprotective layer 24 applied to the active surface 21 of thesemiconductor chip 2. In this regard, the first passivation layer 14includes a plurality of inner openings 141 which are formed therein andare coaxially aligned with respective ones of the openings 241 disposedin the protective layer 24. As a result, each of the pads 23 of the chip2 is exposed in a corresponding coaxially aligned pair of the openings241 and inner openings 141.

In addition to the inner openings 141, the first passivation layer 14includes at least one outer opening 142 which is aligned with the atleast one hole 123 formed in the package body 12. As will be recognized,in the embodiment of the semiconductor device 1 shown in FIG. 1 whereina plurality of through holes 123 are formed in the package body 12 andsurround the semiconductor chip 2, the first passivation layer 14includes a plurality of outer openings 142 formed therein, each of whichis coaxially aligned with a respective one of the holes 123. Thus, inthe semiconductor device 1, the number of outer openings 142 formedwithin the first passivation layer 14 is preferably equal to the numberof holes 123 formed in the package body 12, with each such outer opening142 being aligned with a corresponding hole 123. The first passivationlayer 14 may be formed from a non-conductive polymer such as polyimide(PI), or an epoxy. Alternatively, the first passivation layer 14 may beinorganic, and comprise a material such as silicone dioxide (SiO₂).Still further, the first passivation layer 14 may comprise aphoto-sensitive polymer such as benzocyclobutene (BCB). The formation ofthe first passivation layer 14 may be facilitated through theimplementation of a spin coating or a spray coating process. As seen inFIG. 1, the peripheral side surface defined by the first passivationlayer 14 is preferably substantially continuous or coplanar with theperipheral side surface defined by the package body 12.

The second passivation layer 32 of the upper RDL is disposed on thepatterned conductive layer 31 and the first passivation layer 14. Thesecond passivation layer 32 has a plurality of second openings 321formed therein. The second openings 321 expose portions of respectiveones of the segments defined by the patterned conductive layer 31. Thesecond passivation layer 32 may be formed from a non-conductive polymersuch as polyimide (PI), or an epoxy. Alternatively, the secondpassivation layer 32 may be inorganic, and comprise a material such assilicone dioxide (SiO₂). Still further, the second passivation layer 32may comprise a photo-sensitive polymer such as benzocyclobutene (BCB).The formation of the second passivation layer 32 may be facilitatedthrough the implementation of a spin coating or a spray coating process.As seen in FIG. 1, the peripheral side surface defined by the secondpassivation layer 32 is preferably substantially continuous or coplanarwith the peripheral side surfaces defined by both the first passivationlayer 14 and the package body 12. Those of ordinary skill in the artwill recognize that the first and second passivation layers 14, 32 maybe fabricated from identical or dissimilar materials. Solder balls 34are disposed in the second openings 321 of the second passivation layer32 to contact respective ones of the segments of the patternedconductive layer 31.

In the semiconductor device 1, the upper patterned conductive layer 31electrically connects the pads 23 of the semiconductor chip 2 with theconductive via(s) 15 and with the external contacts or solder balls 34disposed in the second openings 321 of the second passivation layer 32.Thus, the upper RDL provides for signal routing to and from thesemiconductor chip 2 with either an external printed circuit board (notshown) or a second semiconductor device (also not shown) which could beconnected or mounted to the lower RDL.

The lower RDL includes a third passivation layer 36, a backside circuitlayer 38, a fourth passivation layer 39, and at least one lower pad orunder bump metallization 44 (UBM). The third passivation layer 36 isapplied to and covers the second surface 122 of the package body 12. Thethird passivation layer 36 has a plurality of third openings 361disposed therein. Each of the third openings 361 is aligned with andthus exposes a portion of a respective one of the vias 15. The thirdpassivation layer 36 may be formed from a non-conductive polymer such aspolyimide (PI), or an epoxy. Alternatively, the third passivation layer36 may be inorganic, and comprise a material such as silicone dioxide(SiO₂). Still further, the third passivation layer 36 may comprise aphoto-sensitive polymer such as benzocyclobutene (BCB). The formation ofthe third passivation layer 36 may be facilitated through theimplementation of a spin coating or a spray coating process. As seen inFIG. 1, the peripheral side surface defined by the third passivationlayer 36 is preferably substantially continuous or coplanar with theperipheral side surface defined by the package body 12.

The backside circuit layer 38 of the lower RDL is disposed on the thirdpassivation layer 36. The backside circuit layer 38 is patterned todefine a plurality of discrete segments, each of which extends into arespective one of the third openings 361 so as to contact a portion of arespective one of the vias 15. Those of ordinary skill in the art willrecognize that the backside circuit layer 38, and hence each segmentdefined by the patterning thereof, may comprise the combination of aseed layer disposed on the third passivation layer 36 and a conductivelayer which is disposed on the seed layer.

The fourth passivation layer 39 of the lower RDL is disposed on both thebackside circuit layer 38 and the third passivation layer 36. The fourthpassivation layer 39 has a plurality of fourth openings 391 formedtherein. Each of the fourth openings 391 exposes a portion of arespective one of the segments defined by the patterned backside circuitlayer 38. The fourth passivation layer 39 may be formed from anon-conductive polymer such as polyimide (PI), or an epoxy.Alternatively, the fourth passivation layer 39 may be inorganic, andcomprise a material such as silicone dioxide (SiO₂). Still further, thefourth passivation layer 39 may comprise a photo-sensitive polymer suchas benzocyclobutene (BCB). The formation of the fourth passivation layer39 may be facilitated through the implementation of a spin coating or aspray coating process. As seen in FIG. 1, the peripheral side surfacedefined by the fourth passivation layer 39 is preferably substantiallycontinuous or coplanar with the peripheral side surfaces defined by boththe third passivation layer 36 and the package body 12. Those ofordinary skill in the art will recognize that the third and fourthpassivation layers 36, 39 may be fabricated from identical or dissimilarmaterials. The under bump metallizations 44 (UBM's) are disposed in thefourth openings 391 of the fourth passivation layer 39 to contactrespective segments of the patterned backside circuit layer 38.

Referring to FIG. 2, a magnified view of a conductive via 15 of thesemiconductor device 1 and the interconnection to the upper and lowerRDL's is illustrated. In the semiconductor device 1, each through hole123 extends from the first surface 121 of the package body 12 to thesecond surface 122 thereof. A conductive via 15 is disposed within eachthrough hole 123. Each via 15 comprises the combination of a dielectricmaterial 16, a discrete segment of a patterned via seed layer 181, andan interconnection metal 30.

In each via 15, the dielectric material 16 is disposed within and coversthe sidewall of the corresponding hole 123, i.e. the dielectric material16 adheres to a portion of the package body 12 exposed by the throughhole 123. The dielectric material 16 is further is disposed on andcovers the sidewall of the corresponding outer opening 142 of the firstpassivation layer 14 which is coaxially aligned with the hole 123. Adiameter of each outer opening 142 of the first passivation layer 14 isgreater than that of the corresponding hole 123 of the package body 12.As a result, since the first passivation layer 14 is applied to thefirst surface 121 of the package body 12 prior to the formation of thehole 123 therein, during the laser drilling process used to facilitatethe formation of the holes 123, the laser will only drill the packagebody 12, and will not affected by the first passivation layer 14.Therefore, the dielectric material 16 of each via 15 further covers aportion of the first surface 121 of the package body 12. The dielectricmaterial 16 has at least one cavity or bore 161 extending from an uppersurface to a lower surface in a manner as illustrated. Like each throughhole 123, such bore 161 is preferably formed through the use of a laserdrilling process. In this regard, as will be discussed in more detailbelow, in the process of forming each via 15, the dielectric material 16is disposed into each through hole 123 and corresponding outer opening142, with the corresponding bore 161 being subsequently formed in thedielectric material 16. As will also be discussed in more detail below,the via seed layer 181 is thereafter plated directly on to the sidewallof the bore 161, which is thereafter filled with the interconnectionmetal 30.

Referring to FIGS. 3 and 4 in combination, magnified views of aconductive via 15, to include variations in surface roughness areillustrated. In the semiconductor device 1, each through hole 123 isformed through the use of a laser drilling process, and has a preferreddiameter in the range of from about 100 μm to about 500 μm. The packagebody 12 used in the semiconductor device 1 is preferably a compositematerial which includes epoxy resin and SiO₂ fillers 125, with the sizesof the SiO₂ fillers 125 varying from about 10 μm to about 100 μm. Sincethe laser absorption characteristics of the epoxy resin and the SiO₂fillers 125 included in the package body 12 are different, the laserdrilling process used to form the holes 123 causes each such hole 123 todefine a sidewall which is of a first surface roughness value. In thisregard, the first surface roughness value of the sidewall of each hole123 is proportional to the size of the SiO₂ fillers 125 included in thepackage body 12. Typically, the first surface roughness value of thesidewall of the hole 123 is greater than about 20 μm. As indicatedabove, the inclusion of the SiO₂ fillers 125 within the package body 12is the primary cause of the sidewall of each hole 123 having theaforementioned first surface roughness value.

The dielectric material 16 of each via 15 is preferably a polyimide (PT)or a solder mask which does not include the SiO₂ fillers 125 as does thepackage body 12. As a result of the absence of any SiO₂ fillers 125 inthe dielectric material 16, the sidewall of the bore 161 formed by theaforementioned laser drilling process has a second surface roughnessvalue in the range of from about 2 μm to about 20 μm, and typically inthe range of from about 5 μm to about 10 μm. As will be recognized, thesecond surface roughness value of the sidewall of the bore 161 is thustypically less than the first surface roughness value of the sidewall ofthe corresponding hole 123. That is, the sidewall of the bore 161 issmoother than the sidewall of the corresponding hole 123, which providescertain advantages as will be discussed in more detail below. As seen inFIG. 4, the shape of the sidewall of the hole 123 is typically in theform of a non-perfect circle, with the shape of the sidewall of the bore161 more closely approximating a perfect circle. That is, thecircularity value of the bore 161 is greater than that of the hole 123.

Each discrete segment of the patterned via seed layer 181 whichcorresponds to a respective one of the vias 15 is formed on and thuscovers the sidewall of the bore 161 formed in the dielectric material16. In addition, each segment of the patterned via seed layer 181transitions to a corresponding discrete segment of the patterned surfaceseed layer 182 of the upper RDL which is disposed on the firstpassivation layer 14 as indicated above. In the process of fabricatingthe semiconductor device 1, the patterned via and surface seed layers181, 182 are formed at the same time, with each resultant pair ofdiscrete segments thereof corresponding to each via 15 thus beingintegrally connected to each other. Each segment of the surface seedlayer 182 is formed on the first passivation layer 14 so as to extendinto one or more of the inner openings 141 defined thereby, and thusinto contact with one or more of the pads 23 of the semiconductor chip2.

In the semiconductor device 1, both the via seed layer 181 and thesurface seed layer 182 are preferably fabricated from Ti/Cu. Due to thesidewall of each hole 123 being of the first surface roughness valuedescribed above, any attempt to plate the via seed layer 181 directly onsuch sidewall of the corresponding hole 123 would give rise todifficulties in controlling the plating quality of such via seed layer181. In this regard, the thickness of the via seed layer 181 is in therange of from about 2 μm to about 20 μm, thereby making it difficult toplate the same directly on the relatively rough sidewall of the hole123. In accordance with the present invention, each hole 123 is linedwith the dielectric material 16 in the aforementioned manner, with thevia seed layer 181 then being plated onto the sidewall of the bore 161which is of the reduced second surface roughness value, thus overcomingthe roughness issue.

More particularly, in the semiconductor device 1, the first surfaceroughness of the sidewall of each hole 123 is generally attributable tosuch sidewall being partially defined by portions of the SiO₂ fillers125 which protrude from the epoxy. Along these lines, since it iscontemplated that the via seed layer 181 will be formed through the useof the above-described sputtering process, any attempt to form such viaseed layer 181 directly on the sidewall of the hole 123 by eliminatingthe dielectric material 16 would give rise to the same deficiencieshighlighted above. In this regard, the SiO₂ fillers 125 wouldpotentially hinder the complete, uniform application of the via seedlayer 181 to the sidewall of the hole 123, which could in turn lead tothe formation of voids between the interconnection metal 30 filled intothe hole 123 and the sidewall thereof. These voids could increase theresistance of the resultant conductive via, and could further cause adefect upon the completion of a prescribed reliability test (e.g., TCT,HAST).

In contrast to the via seed layer 181 which is typically formed throughthe use of a sputtering process, the dielectric material 16 ispreferably filled into each hole 123 as a fluid, and is thereafter curedto solidify the same. This formation process, coupled with the materialproperties of the dielectric material 16, results in the dielectricmaterial 16 being deposited on the sidewall of the hole 123 withsubstantially less voids being defined therebetween in comparison to thevoids that would result from the direct plating of the via seed layer181 on to the sidewall of the hole 123. Further, since the secondsurface roughness value of the sidewall of the bore 161 formed in thedielectric material 16 is less than the first surface roughness value ofthe sidewall of the hole 123 (the sidewall of the bore 161 thus beingsmoother than the sidewall of the hole 123), there is a substantialreduction in occurrences of void formation between each discrete segmentof the via seed layer 181 and the sidewall of the corresponding bore 161when the sputtering process is used to facilitate the formation of thevia seed layer 181. Thus, the inclusion of the dielectric material 16within each via 15 effectively overcomes many of the difficulties incontrolling the plating quality of the via seed layer 181 which wouldotherwise result from any attempt to plate the same directly onto thesidewall of the hole 123. Along these lines, in comparison to theincreased time and cost that would be needed to achieve adequate platingquality of the via seed layer 181 directly onto the sidewall of the hole123, the time associated with the plating of the via seed layer 181 onto the sidewall of the bore 161 is substantially shorter with theplating quality thereof being easier to control, thus resulting in areduction in the manufacturing cost for the semiconductor device 1coupled with an increase in the reliability thereof.

The interconnection metal 30 of each via 15 of the semiconductor device1 is disposed within the bore 161 of the dielectric material 16 indirect contact with at least a portion of a corresponding segment of thevia seed layer 181. As seen in FIG. 1, the interconnection metal 30 is asolid metal pillar. However, it is also contemplated that theinterconnection metal 30 may alternatively comprise a core of insulationmaterial which is surrounded by a conductive metal material. Thus,within each via 15 of the semiconductor device 1, the interconnectionmetal 30 is surrounded or circumvented by a corresponding segment of thevia seed layer 181, which is in turn circumvented by the dielectricmaterial 16 within the corresponding hole 123.

In the semiconductor device 1, the interconnection metal 30 of each via15 included therein is integrally connected to a corresponding discretesegment of patterned conductive layer 31 of the upper RDL. Theinterconnection metal 30 of each via 15 and the corresponding segment ofthe patterned conductive layer 31 are formed at the same time, and arethus integrally connected to each other. Each segment of the patternedconductive layer 31 is disposed on and extends along a corresponding,underlying segment of the patterned surface seed layer 182 which, asindicated above, is formed on the first passivation layer 14 so as toextend into one or more of the inner openings 141 defined thereby, andthus into contact with one or more of the pads 23 of the semiconductorchip 2. Along these lines, the shape of each segment of the patternedconductive layer 31 is preferably the same as that segment of thepatterned surface seed layer 182 upon which is formed, each segment ofthe patterned conductive layer 31 thus being operative to facilitate theelectrical connection of the interconnection metal 30 of the via 15 towhich it is integrally connected to at least one of the pads 23 of thesemiconductor chip 2. In the semiconductor device 1, the interconnectionmetal 30 of each via 15, and hence the corresponding segment of thepatterned conductive layer 31, is preferably fabricated from Cu. Assuch, each segment of the patterned conductive layer 31 effectivelyfacilitates the electrical connection of one or more of the pads 23 ofthe semiconductor chip 2 to the interconnection metal 30 of a respectiveone of the vias 15 included in the semiconductor device 1.

Referring to FIG. 5, in the semiconductor device 1, the multiple holes123 formed in the package body 12 and extending between the first andsecond surfaces 121, 122 thereof are arranged in a generallyquadrangular (e.g., square) pattern. In this regard, each hole 123 ispositioned between the side surface 25 of the semiconductor chip 2 and aperipheral side surface defined by the package body 12.

FIG. 6 depicts a semiconductor device 1 a constructed in accordance withanother embodiment of the present invention. The semiconductor device 1a is substantially similar to the semiconductor device 1 shown in FIGS.1-5, with only the distinctions between the semiconductor devices 1, 1 abeing highlighted below.

The primary distinction between the semiconductor devices 1, 1 a lies inthe structure of the holes 123 included in the semiconductor device 1 ain comparison to the holes 123 included in the semiconductor device 1.More particularly, whereas each hole 123 in the semiconductor device 1has a generally circular configuration, each hole 123 in thesemiconductor device 1 a has a generally quadrangular (e.g. rectangular)configuration. Due to the increased size of each hole 123 in thesemiconductor device 1 a, the dielectric material 16 disposed thereinmay have a plurality of bores 161 formed therein via a laser drillingprocess, such bores 161 being formed in a prescribed pattern orarrangement. In the exemplary embodiment of the semiconductor device 1 ashown in FIG. 6, only a total of four (4) holes 123 are formed in thepackage body 12. Each of the holes 123 of one opposed pair thereofaccommodates seven (7) vias 15 a, with the remaining opposed pair of theholes 123 each accommodating three (3) vias 15 a. Those of ordinaryskill in the art will recognize that the size and number of vias 15 aaccommodated by each of the holes 123 shown in FIG. 6 is exemplary only,and may be varied without departing from the spirit and scope of thepresent invention.

Referring to FIG. 7, each of the bores 161 formed in the dielectricmaterial 16 disposed in each hole 123 of the semiconductor device 1 ahas a discrete segment of the patterned via seed layer 181 plated ontothe sidewall thereof, and further has a dedicated interconnection metal30 disposed therein. Thus, at least two separate segments of thepatterned via seed layer 181 and two separate interconnection metals 30are disposed in each of the holes 123 of the semiconductor device 1 a.In addition, as indicated above, each hole 123 of the semiconductordevice 1 a accommodates multiple through package body vias 15 a. Eachsuch via 15 a within a corresponding one of the holes 123 of thesemiconductor device 1 a comprises the combination of the singulardielectric material 16 disposed in such hole 123, a dedicated segment ofthe patterned via seed layer 181, and a dedicated interconnection metal30. One of the primary advantages attributable to the structure of thesemiconductor device 1 a is that in the manufacturing process relatedthereto, the time needed for the formation of the holes 123 issubstantially reduced as a result of the reduced number thereof, whichin turn results in higher unit per hour (UPH) productivity in relationto the manufacture of the semiconductor device 1 a. Within each hole123, the pitches between the bores 161 formed in the dielectric material16 filled into such hole 123 can be very small, and typically in therange of from about 10 μm to about 100 μm.

In the semiconductor device 1 a, the outer openings 142 formed in thefirst passivation layer 14 will be sized to accommodate respective onesof the holes 123. In this regard, the quadrangular sidewall defined byeach hole 142 in the first passivation layer 14 of the semiconductordevice 1 a is spaced outwardly relative to the periphery of thecorresponding hole 123 such that the first passivation layer 14 in thesemiconductor device 1 a does not affect the laser drilling process usedto facilitate the formation of each of the holes 123. As a result ofthis relative sizing between each outer opening 142 and thecorresponding hole 123 in the semiconductor device 1 a, the dielectricmaterial 16 disposed in each such hole 123 will cover a portion of thefirst surface 121 of the package body 12, in addition to covering thesidewall of the corresponding outer opening 142 of the first passivationlayer 14.

Referring now to FIGS. 8-21, there is depicted an exemplary sequence ofsteps which may be used to facilitate the fabrication of thesemiconductor device 1 shown in FIGS. 1-5. FIGS. 8-21 depict the processsteps in terms of the fabrication of only a single semiconductor device1. However, those of ordinary skill in the art will recognize that theprocess is typically implemented in manner facilitating the simultaneousfabrication of multiple semiconductor devices 1.

In the initial step of the fabrication process shown in FIG. 8, acarrier, which may comprise a glass plate or a silicon wafer, isprovided and includes an adhesive film 42 applied to one side or facethereof.

In the next step of the fabrication process shown in FIG. 9, at leastone, and preferably a plurality of the semiconductor chips 2, aredisposed on the adhesive film 42 applied to the carrier 40. Eachsemiconductor chip 2 has the above-described protective layer 24 appliedto the active surface 21 thereof prior to its operative engagement tothe adhesive film 42. As further apparent from FIG. 9, the protectivelayer 24 applied to the active surface 21 is engaged directly to theadhesive film 42, with the backside surfaces 22 of the semiconductorchips 2 thus being disposed furthest from the adhesive film 42.

In the next step of the fabrication process shown in FIG. 10, thesemiconductor chips 2 are encapsulated by the package body 12. Moreparticularly, the package body 12 encapsulates or covers the sidesurface 25 and the backside surface 22 of each semiconductor chip 2. Inaddition, the first surface 121 of the package body 12 contacts theadhesive film 42, and is thus substantially continuous or co-planar withthe active surface 21 of each semiconductor chip 2.

In the next step of the fabrication process shown in FIG. 11, thecarrier 40 and the adhesive film 42 are removed, thus exposing the firstsurface 121 of the package body 12 and the protective layer 24 appliedto the active surface 21 of each semiconductor chip 2. For eachsemiconductor chip 2, the pads 23 thereof are effectively exposed withinrespective ones of the openings 241 of the corresponding protectivelayer 24.

In the next step of the fabrication process shown in FIG. 12, the firstpassivation layer 14 is applied to the protective layer 24 of eachsemiconductor chip 2 partially encapsulated by the package body 12. Asshown in FIG. 12, a portion of the first passivation layer 14, inaddition to contacting the protective layers 24 of the semiconductorchips 2, also contacts a portion of the first surface 121 of the packagebody 12. The inner openings 141 of the first passivation layer 14 arecoaxially aligned with respective ones of the openings 241 of theprotective layers 24 to facilitate the exposure of the pads 23 of thesemiconductor chips 2.

In the next step of the fabrication process shown in FIG. 13, amultiplicity of through holes 123 are formed in the package body 12through the use of a first laser 15. As is apparent from FIG. 13, laserenergy from the first laser 15 is applied to portions of the firstsurface 121 of the package body 12 which are exposed in each of theouter openings 142 defined by the first passivation layer 14. In thefabrication step shown in FIG. 13, each hole 123 is a blind hole, andthus does not extend to the second surface 122 of the package body 12 atthis stage. As previously explained, the diameter of each outer opening142 of the first passivation layer 14 is greater than that of thecorresponding hole 123, the first laser 15 thus only drilling thepackage body 12, and not being affected by the first passivation layer14. The wavelength of the first laser 15 is preferably in the range offrom about 254 nm to about 10640 nm. As also indicated above, upon thecompletion of the laser drilling process, the sidewall of each hole 123has a first surface roughness value in the range of from about 5 μm toabout 100 μm attributable to the differences in the laser absorptioncharacteristics of the epoxy resin and the SiO₂ fillers 125 included inthe package body 12.

In the next step of the fabrication process shown in FIG. 14, each hole123 and the corresponding outer opening 142 in the first passivationlayer 14 are filled with the dielectric material 16.

In the next step of the fabrication process shown in FIG. 15, thedielectric material 16 filled into each hole 123 is drilled through theuse of a second laser 17 (which may or may not be the same as device asfirst laser 15), such drilling operation facilitating the formation ofthe bore 161 within the dielectric material 16. The dielectric material16 remains on the sidewall of the corresponding hole 123 and on thesidewall of the corresponding outer opening 142 when the second laserdrilling operation is completed through the use of the second laser 17.As indicated above, the sidewall of the bore 161 defined by the secondlaser drilling process has a second surface roughness value typically inthe range of from about 2 μm to about 20 μm, which is less than theaforementioned first surface roughness value of the sidewall of thecorresponding hole 123. It is contemplated that the wavelength of thesecond laser 17 will be equal to or less than that of the first laser15.

In the next step of the fabrication process shown in FIG. 16, a seedlayer 18, which is preferably formed from Ti/Cu, is plated in each bore161 and on the first passivation layer 14. The seed layer 18 definesboth the via seed layer 181 and the surface seed layer 182 describedabove in relation to the completed semiconductor device 1. Since, asindicated above, the second surface roughness value of the sidewall ofeach bore 161 is less than the first surface roughness value of thesidewall of the corresponding hole 123, the plating time used tofacilitate the formation of the seed layer 18 (and in particular theportion thereof defining the via seed layer 181) is short (therebyreducing fabrication costs), with the plating quality being easy tocontrol and of a high grade. The seed layer 18 is then patterned todefine each pair of the integrally connected discrete segments of thevia and surface seed layers 181, 182 described above. More particularly,as a result of such patterning, the seed layer 18 is caused to definethe via seed layer 181 which is segregated into separate segmentscorresponding to respective ones of the bores 161, and the surface seedlayer 182 which is also segregated into separate segments, each of whichis integrally connected to a corresponding segment of the via seed layer181 and further extends into one or more of the inner openings 141defined by the first passivation layer 14 so as to contact one or moreof the pads 23 of a corresponding semiconductor chip 2.

In the next step of the fabrication process shown in FIG. 17, a metalmaterial, such as Cu, is plated on the via and surface seed layers 181,182. The metal material is then patterned. Such patterning results inthe metal material being formed on each discrete segment of the via seedlayer 181 and filling the corresponding bore 161 to define theinterconnection metal 30 of a corresponding via 15, and the metalmaterial further being formed on each discrete segment of the surfaceseed layer 182 to define a corresponding segment of the patternedconductive layer 31. As previously explained, the interconnection metal30 of each via 15 is preferably a solid metal pillar, though it mayalternatively define a core of insulation material which is surroundedby a conductive metal material.

In the next step of the fabrication process shown in FIG. 18, the secondpassivation layer 32 is formed on the patterned conductive layer 31 andthe first passivation layer 14. The second openings 321 defined by thesecond passivation layer 32 expose portions of respective ones of thesegments defined by the patterned conductive layer 31.

In the next step of the fabrication process shown in FIG. 19, thepackage body 12 is thinned from its second surface 122 by a grinding oretching process. Such grinding or etching process effectively exposesthe interconnection metal 30 of each via 15, and further effectivelycauses each hole 123, originally a blind hole, to become a through hole.

In the next step of the fabrication process shown in FIG. 20, aplurality of contacts 34 such as solder balls are formed in respectiveones of the second openings 321 defined by the second passivation layer32 to contact respective segments of the patterned conductive layer 31.

In the next step of the fabrication process shown in FIG. 21, the thirdpassivation layer 36 is formed on the second surface 122 of the packagebody 12. Each of the third openings 361 defined by the third passivationlayer 36 is aligned with and thus exposes the interconnection metal 30of a corresponding via 15. Subsequent to the formation of the thirdpassivation layer 36, the backside circuit layer 38 is formed on thethird passivation layer 36. The backside circuit layer 38 is patternedto define a plurality of discrete segments, each of which extends into arespective one of the third openings 361 defined by the thirdpassivation layer 36 to contact the interconnection metal 30 of acorresponding via 15. Thereafter, the fourth passivation layer isdisposed on both the backside circuit layer 38 and the third passivationlayer 36. Each of the four openings 391 defined by the fourthpassivation layer 39 exposes a portion of a respective one of thesegments defined by the patterned backside circuit layer 38. Under bumpmetallizations 44 as shown in FIG. 1 are then formed in respective onesof each of the fourth openings 391 defined by the fourth passivationlayer 39.

In the final step of the fabrication process, the package body 12, aswell as the first, second, third and fourth passivation layers 14, 32,36, 39, are then cut or singulated to form a plurality of the individualsemiconductor devices 1 as shown in FIG. 1. In each such semiconductordevice 1, the peripheral side surfaces of the package body 12 and eachof the first, second, third and fourth passivation layers 14, 32, 36, 39are formed as a result of such singulation process. However, eachsemiconductor chip 2 and the via(s) 15 corresponding thereto arepreferably provided with a dedicated seed layer 18, a dedicated metallayer and a dedicated backside circuit layer 38 as each described above.

Referring now to FIGS. 22-27, there is depicted an exemplary sequence ofsteps which may be used to facilitate the fabrication of thesemiconductor device 1 a shown in FIGS. 6-7. The method implemented tofacilitate the fabrication of the semiconductor device 1 a issubstantially similar to that described above in relation to thefabrication of the semiconductor device 1, with only the distinctionsbeing highlighted below.

Referring to FIG. 22, a distinction between the fabrication processesfor the semiconductor devices 1, 1 a lies in the first laser drillingprocess described above in relation to FIG. 13 to form the holes 123 inthe semiconductor device 1 instead being used to form the increased sizeholes 123 of the semiconductor device 1 a. More particularly, in thestep of the fabrication process for the semiconductor device 1 a shownin FIG. 23, the first laser drilling process is completed in a mannerfacilitating the formation of the increased size holes 123, each ofwhich has a generally quadrangular, rather than circular, configuration.

In the next step of the fabrication process shown in FIG. 24, each suchhole 123 of increased size is filled with the dielectric material 16.

In the next step of the fabrication process shown in FIG. 25, the secondlaser drilling process described above in relation to FIG. 15 is carriedout in relation to the dielectric material 16 filled into each hole 123so as to form multiple bores 161 therein.

In the next step of the fabrication process shown in FIG. 26, the seedlayer 18, which is preferably formed from Ti/Cu, is plated in each bore161 and on the first passivation layer 14. The seed layer 18 is thenpatterned to define each pair of the integrally connected discretesegments of the via and surface seed layers 181, 182 described above.More particularly, as a result of such patterning, the seed layer 18 iscaused to define the via seed layer 181 which is segregated intoseparate segments corresponding to respective ones of the bores 161, andthe surface seed layer 182 which is also segregated into separatesegments, each of which is integrally connected to a correspondingsegment of the via seed layer 181 and further extends into one or moreof the inner openings 141 defined by the first passivation layer 14 soas to contact one or more of the pads 23 of a correspondingsemiconductor chip 2. Thus, the seed layer 18 defines both the via seedlayer 181 and the surface seed layer 182 in the completed semiconductordevice 1 a.

In the next step of the fabrication process shown in FIG. 27, a metalmaterial, such as Cu, is plated on the seed layer 18. The metal materialis then patterned. Such patterning results in the metal material beingformed on each discrete segment of the via seed layer 181 and fillingthe corresponding bore 161 to define the interconnection metal 30 of acorresponding via 15 a, and the metal material further being formed oneach discrete segment of the surface seed layer 182 to define acorresponding segment of the patterned conductive layer 31. Thesubsequent steps used to facilitate the fabrication of the semiconductordevice 1 a are similar to those shown and described above in relation toFIGS. 18-21.

While the invention has been described and illustrated with reference tospecific embodiments thereof, these descriptions and illustrations donot limit the invention. It should be understood by those skilled in theart that various changes may be made and equivalents may be substitutedwithout departing from the true spirit and scope of the invention asdefined by the appended claims. The illustrations may not be necessarilybe drawn to scale. There may be distinctions between the artisticrenditions in the present disclosure and the actual apparatus due tomanufacturing processes and tolerances. There may be other embodimentsof the present invention which are not specifically illustrated. Thespecification and the drawings are to be regarded as illustrative ratherthan restrictive. Modifications may be made to adapt a particularsituation, material, composition of matter, method, or process to theobjective, spirit and scope of the invention. All such modifications areintended to be within the scope of the claims appended hereto. While themethods disclosed herein have been described with reference toparticular operations performed in a particular order, it will beunderstood that these operations may be combined, sub-divided, orre-ordered to form an equivalent method without departing from theteachings of the invention. Accordingly, unless specifically indicatedherein, the order and grouping of the operations are not limitations ofthe invention.

What is claimed is:
 1. A semiconductor device, comprising: asemiconductor chip including a plurality of conductive pads; a packagebody at least partially encapsulating the semiconductor chip and havinga top surface and bottom surface opposite to the top surface, thepackage body being a composite material which includes resin andfillers; a conductive layer disposed on the bottom surface of thepackage body; and at least one through via within the package body andelectrically connected to the conductive layer, the via extending fromthe conductive layer and protruding out of the top surface of thepackage body; wherein: the package body has at least one hole formedtherein defining a hole sidewall and the via is disposed in the hole andcomprises a dielectric material which is disposed on the hole sidewallof the hole; the hole sidewall is partially defined by portions of thefillers protruding from the resin and is of a first surface roughnessvalue; and the dielectric material defines at least one bore having abore sidewall which is of a second surface roughness value less than thefirst surface roughness value.
 2. The semiconductor device of claim 1wherein the first surface roughness value of the hole sidewall is in therange of from about 5 μm to about 100 μm.
 3. The semiconductor device ofclaim 1 wherein the second surface roughness value of the bore sidewallis in the range of from about 2 μm to about 20 μm.
 4. The semiconductordevice of claim 1 wherein the resin is epoxy resin and the fillers areSiO2 fillers.
 5. The semiconductor device of claim 1 wherein the viafurther comprises: a seed layer disposed on the bore sidewall thereof;and an interconnection metal which is disposed within the bore and on atleast a portion of the seed layer.
 6. The semiconductor device of claim5 further comprising a conductive layer which is integrally connected tothe interconnection metal and facilitates the electrical connectionthereof to at least one of the pads of the semiconductor chip, theconductive layer overlying a portion of the seed layer.
 7. Thesemiconductor device of claim 1 wherein at least two through packagebody vias are disposed in the hole, each of the vias comprising arespective one of at least two bores which are defined by the dielectricmaterial and each have a bore sidewall which is of the second surfaceroughness value less than the first surface roughness value.
 8. Thesemiconductor device of claim 7 wherein each of the vias furthercomprises: a seed layer disposed on the bore sidewall thereof; and aninterconnection metal which is disposed within the bore thereof and onat least a portion of the seed layer thereof.
 9. The semiconductordevice of claim 7 wherein: the first surface roughness value of the holesidewall is in the range of from about 5 μm to about 100 μm; and thesecond surface roughness value of the bore sidewall of each of the boresdefined by the dielectric material is in the range of from about 2 μm toabout 20 μm.
 10. A semiconductor device, comprising: a semiconductorchip; a package body at least partially encapsulating the semiconductorchip and having a top surface and a bottom surface opposite to the topsurface, the package body being a composite material which includesresin and fillers; a conductive layer disposed on the bottom surface ofthe package body; and a plurality of through vias within the packagebody and surrounding the semiconductor chip, each of the vias beingelectrically connected to and extending from the conductive layer, andprotruding out of the top surface of the package body; wherein: thepackage body has a plurality of holes formed therein and each of thevias is disposed in a respective one of the holes; each of the viascomprises dielectric material disposed within a corresponding one of theholes and defining a via surface; each of the holes defines a holesidewall which is partially defined by portions of the fillersprotruding from the resin and is of a first surface roughness value; andthe via surface defined by the dielectric surface is of a second surfaceroughness value less than the first surface roughness value asfacilitates an increase in the plating quality of another portion of thevia which is formed on the via surface.
 11. The semiconductor device ofclaim 10 wherein the first surface roughness value of the hole sidewallis in the range of from about 5 μm to about 100 μm.
 12. Thesemiconductor device of claim 10 wherein the second surface roughnessvalue of the via surface is in the range of from about 2 μm to about 20μm.
 13. The semiconductor device of claim 10 wherein the resin is epoxyresin and the fillers are SiO2 fillers.
 14. The semiconductor device ofclaim 10 wherein each of the vias further comprises: a seed layerdisposed on the via surface; and an interconnection metal which isdisposed on at least a portion of the seed layer.
 15. The semiconductordevice of claim 14 further comprising a conductive layer which isintegrally connected to the interconnection metal and facilitates theelectrical connection thereof to the semiconductor chip, the conductivelayer overlying a portion of the seed layer.
 16. The semiconductordevice of claim 10 wherein at least two through package body vias aredisposed in each of the holes.
 17. The semiconductor device of claim 16wherein: a dielectric material which is disposed within each of theholes defines the via surface of each of the vias disposed therein; aseed layer is disposed on the via surface of each of the vias; and aninterconnection metal is disposed on at least a portion of the seedlayer of each of the vias.
 18. A semiconductor device, comprising: asemiconductor chip; a package body at least partially encapsulating thesemiconductor chip, the package body having a top surface and bottomsurface opposite to the top surface, and being a composite materialwhich includes resin and fillers and has at least one hole formedtherein defining a hole sidewall which is partially defined by portionsof the fillers protruding from the resin and is of a first surfaceroughness value; a conductive layer disposed on the bottom surface ofthe package body; and at least one through package body via disposed inthe hole, the via being electrically connected to and extending from theconductive layer, and comprising: a dielectric material disposed on thehole sidewall and defining at least one bore having a bore sidewall; anda seed layer which is plated onto at least a portion of the boresidewall, the bore sidewall being of a second surface roughness valueless than the first surface roughness value as facilitates an increasein the plating quality of the seed layer thereto; the via being formedto protrude out of the top surface of the package body.